Improved air conditioning module

ABSTRACT

An air conditioning module comprises an insulated casing separated into a first air chamber and a second air chamber by an insulated divider. The first air chamber provides a sealed air passageway along the outside of a sound isolation enclosure and between two spaced locations of an inside of the sound isolation enclosure. The second air chamber provides a sealed air passageway between two spaced locations of a room within which the sound isolation enclosure is installed. The air conditioning module has an intake and an exhaust that form the two spaced locations of the second air chamber. Disposed between the intake and exhaust and within the second air chamber is an air circulation means and a condenser unit of a heat exchanger. The air conditioning unit further includes an inlet connector and an outlet connector arranged to seal to an outlet aperture and inlet aperture of the sound isolation enclosure respectively. Disposed between the inlet connector and outlet connector and within the first air chamber is an circulation means and an evaporation unit of a heat exchanger.

The present invention relates to an improved air conditioning module and in particular to an air conditioning module suitable for installation with a sound isolation enclosure.

Sound isolation enclosures are becoming an increasingly popular addition to office space. The sound isolation enclosure is a booth or pod placed within a room such as an office environment and can be referred to as a room within a room. Hereafter, the external office environment will be termed the ‘room’ and the internal room created by the sound isolation enclosure will be termed the ‘enclosure’. The sound isolation enclosure is used as a sound-proofed enclosure, for instance for use as a sound recording studio, to keep sound from the room out of the enclosure, or confidential room in a solicitors office, to keep sound from the enclosure out of the room. The sound insulation typically aims to eliminate air flow between the room and enclosure as these paths can also carry sound. Consequently the sound isolation enclosure is a substantially sealed room that quickly heats up even from small heat sources such as people or computer equipment.

There is a need for air conditioning modules to supply cooled air to the sound isolation enclosure to prevent hot conditions within the enclosure. Such hot conditions may lead to extreme discomfort for the occupiers, and may furthermore cause excessive sweating which in itself leads to drips causing undesirable background noise which may interfere with the function of the sound-proofed room. Therefore some form of cooling within the sound-proofed room is essential.

At present, large and complex fan-assisted air conditioning systems are employed. Such air conditioning modules comprise a refrigeration unit and a ducted unit. The refrigeration unit is typically mounted on the outside of a building and supplies refrigerant to the ducted unit in a closed loop. The ducted unit has an air inlet and an air outlet with a circulation fan to draw air over a radiator (heat is removed by the refrigerant). Conduits run from the ducted unit to disperse the cooled air into the room being cooled. However, the sound isolation enclosures can be temporary and are often installed after installation of the air conditioning system in the room. Consequently, there is not always a ducting available to supply the cooled air from the room's air conditioning system to the enclosure. Furthermore, use of the room's air conditioning system would entail a hole through the enclosure to allow connection of the ducting. This hole provides a passage for sound to travel between the room and enclosure.

Fan based ducted units are standard equipment, which typically, during operation, emit a noise of around 32 decibels. However, by using silencers and increasing the size of the ducting from around 200 millimetres diameter to 600 millimetres diameter, specific units have been able to operate at a noise level of around 19 decibels. However, the noise needs to be below about 12 decibels inside a recording studio.

It is an aim of the present invention to attempt to overcome at least one of the above or other disadvantages. It is a further aim to provide an air conditioning module for use with a sound isolation enclosure that provides effective cooling to the enclosure whilst substantially maintaining the integrity of the sound proofing and without producing disruption to the room.

According to the present invention there is provided an air conditioning module for use with a sound isolation enclosure, a sound isolation enclosure including the same, and a method of installing the air conditioning module to the sound isolation enclosure as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and the description which follows.

There is provided an air conditioning module for sealing to inlet and outlet apertures of a sound isolation enclosure. The air conditioning module has an insulated casing divided into first and second air chambers by an insulated divider. The first air chamber is in fluid communication with an inlet connector and an outlet connector wherein the inlet connector and outlet connector are adapted to seal to the inlet and outlet apertures of the sound isolation enclosure. Arranged within the first air chamber is a first air circulation device for drawing air through the inlet connector and expelling air out of the outlet connector. The first air chamber also includes an evaporator. The second air chamber has an intake in fluid communication with the outside of the casing and an exhaust also in fluid communication with the outside of the casing. Arranged within the second air chamber is a second air circulation device for drawing air through the intake and expelling air out of the exhaust. The second air chamber also includes a condenser. The condenser and evaporation unit forming a heat exchanger.

Advantageously, because the casing insulates both the air chambers, the noise disruption to the room and enclosure can be reduced. Moreover, the insulated divider prevents noise transfer between the air chambers. For instance, air in the second air chamber is caused to move there through by the air circulation means at a quicker rate than air in the first air chamber. This creates more turbulent and therefore noisier air flow. Here the insulated divider provides a barrier to prevent noise transfer from the second air chamber to the first air chamber. Providing the two air chambers in an insulated housing provides a module that can be installed on the outside of the enclosure but within the room easily and conveniently. For instance, the insulated casing may have a coupling for connecting with a cooperating coupling on the sound isolation enclosure. By connecting the couplings on the insulated casing and sound isolation enclosure, the air conditioning module can be easily and conveniently installed.

In the exemplary embodiments the couplings form interlocking elements. For instance the couplings may be cooperating protrusions and channels that key together. Here the keying may be achieved by relative movement of the air conditioning module with the sound isolation enclosure. This allows the air conditioning module to be disconnected by the reverse movement. To achieve the seal between the inlet and outlet apertures of the sound isolation enclosure and the inlet connector and an outlet connector of the air conditioning module, sealing means is provided. In the exemplary embodiments, the seal is formed by joining the couplings. Suitably, the sealing means are face seals on one or both of the air conditioning module and sound isolation enclosure. The or each face seal forms a perimeter about the respective aperture and connector.

In an exemplary embodiment, the couplings are arranged to interconnect by linear relative movement. The linear movement causes the sealing means to seal between the aperture and connector. For instance, suitably the sealing means is a face seal the is brought into an arrangement whereby the face seal seals the respective connector and aperture due to the linear movement. Suitably, the liner movement is in a vertical direction so that the mass of the air conditioning module acts in the coupling direction. This also means the couplings support the air conditioning module. The couplings may also be arranged to cause movement of the air conditioning module respectively towards the sound isolation enclosure. Said movement towards each other helps to squeeze the sealing means to form a correct seal.

In the exemplary embodiments the first air chamber is elongate. Preferably, the inlet and outlet connectors are arranged at opposed distal ends of the elongate first air chamber. Suitably, the first air chamber is arranged to be elongate in a substantially vertical direction. Advantageously, the outlet aperture of the sound isolation enclosure is arranged towards a ground of the sound isolation enclosure. Furthermore, it is advantageous for the inlet aperture of the sound isolation enclosure to be arranged towards a ceiling of the sound isolation enclosure. Here the first air chamber provides an elongate passageway on the outside of the sound isolation enclosure that is sealed to the inlet and outlet apertures. The casing is preferably sealed directly to the sound isolation enclosure without the need for long expanses of ducting.

In the exemplary embodiments the second air chamber is elongate. Preferably, the intake and exhaust are arranged at opposed distal ends of the elongate second air chamber. Suitably, the second air chamber is arranged to be elongate in a substantially vertical direction. Advantageously, the intake is arranged towards a ground level of the room. Furthermore, it is advantageous for the exhaust to be arranged towards a ceiling of the room. Here, the second air chamber forms an insulated passageway on the outside of the sound isolation chamber but within the room.

In the exemplary embodiments, the first air chamber and second air chamber are positioned side-by-side. Preferably in a parallel arrangement. Here, in the embodiments comprising elongate, vertical air chambers, the first and second air chambers may be arranged side-by side across a wall of the sound isolation enclosure so that the insulated divider of the insulated casing that forms the two air chambers is arranged at an angle to the wall to which the air conditioning module is to be attached. Alternatively, the insulated divider of the insulated casing that forms the two air chambers may be arranged parallel to the wall to which the air conditioning module is to be attached. In this case, it is advantageous to arrange the first air chamber against the sound isolation chamber to separate the noisier second chamber from the sound isolation enclosure.

In one exemplary embodiment, the air conditioning module is formed from a first section connected to a second section. Suitably, the first section is sealed to the second section. Here, elongate first and second air chambers are formed by connecting the first and second sections. In this case, one of the first or second sections includes the inlet connector and intake along with a first portion of the insulated casing and insulated divider and the other of the sections includes the outlet connector and exhaust along with a second portion of the insulated casing and insulated divider. This allows the elongate air conditioning module to be transported as a more compact unit that is more likely to be able to fit through access doors, passageways and lifts to the room. In one exemplary embodiment, the two sections are hinged together to make connection easier but other connections are envisaged. Furthermore, it may be advantageous to provide the air conditioning module with movement means such as wheels to transport the air conditioning module.

The heat exchanger may further comprise a compressor to compress the refrigerant and a pump or circulation means to circulate the refrigerant around the condenser and evaporator. Further features of the heat exchanger as well known in the art may be added as necessary. The air conditioning module providing a housing for all the parts of the heat exchanger. Preferably, to limit connections through the insulated casing, the parts where possible should be installed within the air chambers.

Consequently, there is provided an air conditioning module that provides a convenient and acceptable way of cooling a sound isolation pod that limits the adverse effect on the room.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

FIG. 1 is a cross sectional side view of an exemplary air conditioning module attached to a sound isolation pod;

FIG. 2 is a cross sectional view through line A-A of FIG. 1;

FIG. 3 is a cross sectional view through line B-B of FIG. 1; and

FIG. 4 is a side view of a further exemplary embodiment.

Referring to FIG. 1 an air conditioning module 100 is shown. The air conditioning module 100 comprises an insulated casing 101 separated into a first air chamber 110 and a second air chamber 120 by an insulated divider 102. The insulated casing 101 and insulated divider 102 are sound insulated and typically clad with acoustic foam or the like to absorb sound and prevent sound being transferred through the divider 102 or casing 101. The first air chamber 110 provides a sealed air passageway along the outside of a sound isolation enclosure 200 and between two spaced locations of an inside 202 of the sound isolation enclosure 200. The second air chamber 120 provides a sealed air passageway between two spaced locations of a room 300 within which the sound isolation enclosure 200 is installed. The air conditioning module 100 has an intake 122 and an exhaust 124. The intake 122 and exhaust 124 form the two spaced locations of the second air chamber 120. Disposed between the intake 122 and exhaust 124 and within the second air chamber 200 is an air circulation means 126 and a condenser unit 132 of a heat exchanger 130. The air conditioning module 100 further includes an inlet connector 112 and an outlet connector 114. The inlet connector 112 and outlet connector 114 are arranged to seal to an outlet aperture 212 and inlet aperture 214 of the sound isolation enclosure 200 respectively. Disposed between the inlet connector 112 and outlet connector 114 and within the first air chamber 110 is an circulation means 116 and an evaporation unit 134 of a heat exchanger 130.

In use, the circulation means 116 causes air to move from the inlet connector 112 towards the outlet connector 114. Air drawn from the outlet aperture 212 of the sound isolation enclosure 200 flows over the evaporation unit 134 and is caused to cool. The cool air is expelled from the outlet connector 114 and back into the sound isolation enclosure 200 to cool the inside 202. The air circulation means 126 causes air to flow from the intake 122 toward the exhaust 124. Air drawn through the intake 122 passes over the condenser unit 132 and is caused to warm. The warm air is expelled through the exhaust 124.

The sound isolation enclosure 200 is formed from components forming side walls 202 a, a ceiling 202 b, and a floor 202 c to form a sealed and sound insulated enclosure. Although not shown, it will be appreciated that an entrance is also provided. The inside 202 may be furnished to suit the application, for instance with furniture and electrical equipment. Any supplies required through the components are minimised to prevent sound bridges and thus are carefully insulated. For instance, through holes may be provided to supply power and data cables to the electrical equipment. In addition the outlet 212 and inlet 214 are also formed by creating through holes from the inside 202 to the outside room 300. As shown, suitably the through holes are formed through a side wall 202 a. As will be explained herein, preferably the air conditioning module 100 is elongate allowing the inlet 214 and outlet 212 to be arranged towards the ceiling 202 b and floor 202 c, respectively. Since hot air rises, drawing air from the floor and expelling the cooled air in to the top of the enclosure 202 causes an advantageous circulation and cooling effect within the enclosure 202. Although the sound isolation enclosure 200 is described in conjunction with a room 300, the sound isolation enclosure 200 may be a truck or a compartment within a truck to prevent transfer outside of the truck.

The casing of the air conditioning module 100 is provided with a coupling to connect to a cooperating coupling on the sound isolation enclosure 200. Although not shown, the coupling may be a simple fixing such as a screw bolt or adhesive. However, preferably, the coupling is a keying mechanism such as a protrusion keying into a hole by relative movement. This allows the air conditioning module 100 to be detachably connected to the sound isolation enclosure.

The inlet 112 and outlet 114 connectors of the air conditioning module 100 are sealed to the inlet 214 and outlet 212 apertures of the sound isolation enclosure 200. Here the inlet 112 and outlet 114 connectors may be protrusions extending from the insulated casing 101, wherein the protrusions cooperatively engage the apertures 214,212. However, as shown in the figures, the inlet 112 and outlet 114 connectors may be simple apertures formed through the insulated casing 101. Referring to FIG. 2, the apertures 214,212 are elongate and extend a substantial distance across the first air chamber 110. For instance, the apertures 214,212 may extend at least 60% of a width across the first air chamber 110, or at least 70% or 75% of the width. The inlet 214 and outlet 212 apertures in the sound isolation enclosure 200 substantially correspond in shape and size. To seal the inlet 214 and outlet 212 apertures to the inlet 112 and outlet 114 connectors, seals 140 are provided. Any type of suitable seal may be used, but as shown it is advantageous to use face seals that can be made by relative movement of the air conditioning module 100 to the sound isolation enclosure 200. The face seals surround the connectors 112,114. Suitably, the face seals are a gasket such as a foam gasket. The seals may be arranged to be under compression when the air conditioning module 100 is connected to the sound isolation enclosure 200. FIG. 2 shows the seals 140 assembled to the insulated casing 101, for instance by adhesive or a mechanical fixing. However, it will be appreciated that the seals 140 may equally be affixed to the sound isolation enclosure 200.

Referring back to FIG. 1, the inlet 214 and outlet 212 apertures in the sound isolation enclosure 200 are suitably shown arranged towards the ceiling 202 b and floor 202 c, respectively. The air conditioning module 100 is therefore arranged to be elongate so as to extend a substantial distance along the height of the sound isolation enclosure 200. As explained, the air conditioning module 100 is suspended from the sound isolation enclosure 200, which allows the intake 122 of the second air chamber 120 to be suitably arranged on an underside of the insulated casing 101 as a gap at the bottom of the sound isolation enclosure 200 is left. The elongate air conditioning module 100 has a width, height and depth. As shown, the height is generally substantially greater than the width or depth and may be greater than 200% of the width or depth or more than 300% or more than 400% greater. The width may be greater than 200% of the depth or more than 300% or more than 400% greater. The heat exchanger 130 may be arranged in a lower section of the air chambers 110,120 so that the air drawn into the chambers 110,120 travels a shorter distance to the heat exchanger 130 than the distance the air travels between the heat exchanger 130 and exhaust 124/outlet 114 connector. A deflector 118 such as a concave deflector 118 may be installed within the air chambers 110,120 around any of the inlet 214, outlet 212, intake 122 and exhaust 124 so as to guide the air flow. For instance deflector 118 is shown in FIG. 1 toward the outlet connector 114 to guide air from flowing generally along the elongate first air chamber 110 to be directed at an angle through the inlet aperture 214.

Referring to FIG. 3, the second air chamber 120 is also elongate and suitably matched in size and shape to the first air chamber 110. The intake 122 is arranged towards the bottom of the insulated casing 101 so as to draw in cooler air from the room 100. The intake 122 is shown as a hole formed substantially across the bottom of the second air chamber 120. For instance, the air chamber is formed suitably from a plurality of panels. Each panel has an external skin providing a suitable finish and a sound insulation layer, such as a layer of acoustic foam. The plurality of panels typically includes a front, back, first side, second side, top and bottom. The panels are substantially sealed together to form a box between which the insulated divider 101 b runs. Here, the bottom panel does not extend across the second air chamber. The exhaust is suitably arranged at the top of the insulated casing 101. As shown in FIG. 3, the exhaust is suitably shown as apertures through the sides of the insulated casing 101, though the exhaust may also extend through the top of the insulated casing 101. Grills 128 may be installed.

Although the first air chamber 110 and second air chamber 120 may be arranged side-by-side across the width of the sound isolation enclosure 200, they are shown in back-to-back relationship in FIG. 1. Furthermore, the first air chamber 110 and second air chamber 120 may be arranged in a top-to-bottom relationship where either the first air chamber 110 or second air chamber 120 is on top of the other. Suitably, this enables the first chamber 110 to provide additional sound insulation between the second air chamber 120 and sound isolation enclosure 200. Here, the first 110 and second 120 air chambers may be assembled separately as first and second insulated sub-casing joined together at one face to form the insulated divider 102 or the insulated casing 101 may be formed integrally and divided by the divider 102.

Referring to FIGS. 2 and 3, the heat exchanger 130 may comprise further standard air conditioning equipment such as a compressor 135, condensate evaporator 136, drip tray 137 and electrical controller 138. The equipment is installed substantially within the first 110 and second 120 air chambers. The condenser unit and evaporator unit is suitably a condenser coil and evaporator coil respectively as are well known in the art.

FIG. 4 shows an exemplary embodiment wherein the insulated casing 101 is formed from a lower casing 101 a and an upper casing 101 b. The casing 101 is formed in multiple parts to allow easier transportation. The upper casing 101 b is moveable between a stowed position, wherein the upper 101 b and lower 101 a casings are in a compact arrangement, and an installed arrangement, wherein the upper 101 b and lower 101 a casings are assembled ready for use. Here, the upper 101 b and lower 101 a casings are suitably hinged together to allow the upper casing 101 b to move between a side-by-side relationship to a stacked relationship. Fixings 103 are used to keep the upper 101 b and lower 101 a casings in the stacked relationship. Although not shown, seals are used to seal the upper 101 b and lower 101 a casings to provide continuously sealed first 110 and second 120 air chambers between the upper 101 b and lower 101 a casings. Wheels 105 are provided on each of the upper 101 b and lower 101 a casings to allow the air conditioning module 100 to be easily moved or the air conditioning module 100 can be arranged on a moveable platform.

Although a few preferred embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims. 

1. An air conditioning module (100) for sealing to an inlet aperture (214) and an outlet aperture (212) of a sound isolation enclosure (200) installed within a room (300) and so as to provide cool air to the sound isolation enclosure (200), the air conditioning module (100) comprising: an insulated casing (101); an insulated divider (102) that divides the insulated casing (101) in to a first air chamber (110) and a second air chamber (120); a first air circulation means (116) to move air through the first air chamber (110); and a second air circulation means (126) to move air through the second air chamber (120); wherein the first air chamber (110) includes an inlet connector (112) and an outlet connector (114) that are adapted to seal to said inlet (214) and outlet (212) apertures of the sound isolation enclosure (200) and the first air chamber (110) provides a fluid path between the inlet connector (112) and outlet connector (114); the second air chamber (120) includes an intake (122) and an exhaust (124) that are in communication with said room (300) and the second air chamber (120) provides a fluid path between the intake (122) and exhaust (124); and a heat exchanger (130) is arranged within the first (110) and second (120) air chambers to transfer heat from one air chamber to the other.
 2. The air conditioning module (100) of claim 1, wherein the first (110) and second (120) air chambers are elongate.
 3. The air conditioning module (100) of claim 2, wherein the heat exchanger (130) is spaced closer to the inlet connector (112) than the outlet connector (114).
 4. The air conditioning module (100) of any of claims 1 to 3, wherein the insulated casing (101) is arranged such that when the air conditioning module (100) is sealed to the inlet (214) and outlet (212) aperture of the sound isolation enclosure (200), the first air chamber (110) is arranged between the sound isolation enclosure (200) and second air chamber (120).
 5. The air conditioning module (100) of any of claim 4, wherein seals (140) are provided on the insulated casing (101).
 6. The air conditioning module (100) of claim 5, wherein the seals (140) are first and second face seals that surround the inlet (112) and outlet (114) connectors respectively.
 7. The air conditioning module (100) of any of claim 6, wherein the insulated casing (101) includes a first connector for cooperatively connecting to a second connector on the sound isolation enclosure (200).
 8. The air conditioning module (100) of claim 7, wherein the first connector is adapted to connect to the second connector by relative movement of the air conditioning module (100) and sound isolation enclosure (200).
 9. The air conditioning module (100) of any of claim 8, wherein the insulated casing (101) is formed from a lower casing (101 a) and an upper casing (101 b), wherein each of the upper (101 b) and lower (101 a) casings comprise a portion of each of the first (110) and second (120) air chambers, wherein the upper casing (101 b) is moveable between a stowed position and an installed position.
 10. A sound isolation enclosure (200) including an air conditioning module (100) of any of claim 9 sealed to inlet (214) and outlet (212) apertures through the sound isolation enclosure (200), wherein the air conditioning module (100) is installed on an outside of the sound isolation enclosure (200).
 11. The sound isolation enclosure (200) of claim 10, wherein the inlet aperture (214) is installed in a ceiling region of a side wall (202 a) of the sound isolation enclosure (200), and the outlet aperture (212) is installed in a floor region of a side wall (202 a) of the sound isolation enclosure (200).
 12. A method of installing an air conditioning module (100) to a sound isolation enclosure (200) installed within a room (300), the method comprising: installing the air conditioning module (100) by sealing an inlet connector (112) and an outlet connector (114) of the air conditioning module (100) to an outlet aperture (212) and inlet aperture (214) respectively of the sound isolation enclosure (200).
 13. The method of claim 12, wherein the method comprises moving the air conditioning module (100) relative to the sound isolation enclosure (200) to cause first and second connections on the air conditioning module (100) and sound isolation enclosure (200) to cooperatively engage to suspend the air conditioning module (100) from the sound isolation enclosure (200).
 14. The method of claim 12, wherein the method comprises moving an upper casing (101 b) from a stowed position to an installed position before installing the air conditioning module (100) to the sound isolation enclosure (200). 